Method of making tubular sheet-metal spokes for wheels



f '1,498,771 T. N. AnKENs j METHD oF MAKING TUBULAR SHEET 'METALSPKESFOR WHEEL-s Fired' Aug. 29. 1921 4 Skaggs-sheet 2 Wi/Wag.

une 24 1924. 1,498,771-5 T. N. AIKENS v METHOD vOF'PMKIMr TUBULAR SHEETMETAL SPOKS FOR WHEELS WTHQD @E n .t i f` Application led August 39,'1921. ,Serial no. 498,373.' n

To all whom t may concern:

Be it known that l, THOMAS N. Arnnns, a citizen of the United States,residing at Lakewood, in the county of Cuyahoga and State of Ohio, haveinvented a certam new and useful Improvement in Methods of MakingTubular Sheet-:Metal Spokes 4for Wheels, of which the following is aill, clear, and exact description.

ln my co-pending application, Serial No. 487,292, died July 25, 1921, lhave shown., described and claimed a fabricated steel wheel havingspokes, each formed of one piece of sheet metal in tubular forni, withthe edges of the sheet locked together in the form of; a seam extendingfrom one end of the spoke to the other. IThe outer vend of the spoke hasa reduced part which may be fastened in several ways to the el-` loe,and the .inner or hub end of the spoke has an enlarged wed e-shapedportion with twof opposite tapere faces designed to engage thecorresponding faces of the adjacent spokes, .and provided on theopposite tapered faces with projections and depressions respectivelyadapted to interlock with corresponding depressions and projections ofthe adjacent spokes. ln the preferred construction of the spokes thetapered faces are provided also with semi-cylindrical transversedepressions, which when the spokes are assembled, form with the similardepressions on the adjacent spokes, cylindrical openings adapted toaccommodate bolts for clamping the hub portions of the spokes betweenthe flanges of the hub.

This provides a spoke which aside from the interlocking and bolt holefeatures in the hub portions,is similar in appearance to an ordinarywooden spoke. ut the spoke thus produced in tubular form from sheetmetal with a longitudinally extending seam and with the hub portionadapted -to interlock with the adjacent spokes, has

advantages over wooden spokes in the way of increased strength andgreater durability.

' The present invention relates to the meth` od of i'forming a spokesuch as claimedV in my prior application and 'briefly described above,and has for its object to provide a method by which the spoke may beformed effectively and inexpensively.

The invention may be briey summarized as consisting in the novel stepsof the improved method which are described in the specification,illustrated in the drawing, and set forth 1n. the appended claims. L

In the accompanying sheets of drawings showing the method in itspreferred forum Fig. 1 is 'a face view of the blank vwhich 1s cut awayfrom a sheet of metal, and from which the complete spoke is formed; Fig.2 is a plan View of the artially vconnp'leted spoke consisting of aouble or twin section' which is produced from the blank in accordancevwith my process; Fig. ,3 is a side elevation of the same; Fig. tis anend view looking toward the right of Fig. 3;

Fig. 5 is an end view looking 4toward the left of Fig. 3; Figs. 6 and 7are views corresponding to` Figs. d and 5, illustrating the( 'changeswhich are elected `in the edge portions of the double or twin section bya subsequent operation; Figs. 8 and 9 are views corresponding to Figs. 2and 3, showing the partially completed spoke at the end of a furtherspoke forming operation; Figs. 10 and 11 are end views or the partiallycompleted spoke shown in Figs. 8 and 9 looking toward the right andtoward the left respectively of Fig. 9; Figs. 12, 13, 14 and 15 arediagrammatic views illustrating steps or portions of a still urtion;Figs. 17 and 18 are end views 'of the same looking respectively towardthe right and leftvof Fig. 16; Figs. 19 and 2O are respectively a planand side elevation of the jiinished spoke as produced in the final spokeforming operation; Fig. 21

is an end view of the same looking toward the left of Fig. 20; and Figs.22 and 23 are respectively an end view and a plan view of the hubportion of the finished spoke showing a slight modication.

ln the blanking out such as shown at 10 in ig. 1 are punched out from astri of sheet metal of the proper ganga' prefera ly sheet steel. Anordinary punch press may be used for this purpose. lt will be observedthat this blank is wider at? one end than at the other, and that at oneend, i. e. the left hand end as shown in Fi. 1, the blank has a reducedportion 10 whic recess, dat blanks is utilized in forming the reducedend of the spoke which is adapted to be fitted to the felloe. Next thereis an outwardl flared portion 10b which forms the slig tly tapered bodyportion of the spoke. Next there is an outwardly flared portion 10,which forms the outwardly dared part of the s oke leading to theenlarged wedge-shape hub ortion, and next there is the portion 10d w ichis inwardly dared and forms the tapered or wedge-shaped hub portion, thetwo opposite tapered faces of which are adapted to engage and to beinterlocked with the similar portions of adjacent spokes as alreadystated.

From this blank the spoke is formed by several distinct spoke formingoperations, in the first of which, the partially formed spokeillustrated in Figs. 2 to 5 is formed by dies which form no part of thepresent invention. While the partially formed spoke illustrated in thesefigures is stated to be formed by the first spoke forming "operation it1s not to be inferred that the article here illustrated is produced byone stroke of the press and by one drawing operation as the drawing maybe done gradually inl a succession of steps which, however, forconvenience are described as the first forming operation. Additionally,for convenience the other partially formed spokes and finally thecompleted spoke herein illustrated are described as produced by thesecond, third, fourth, fifth and sixth spoke forming operations but oneor more of these operations may each be performed in a series of steps.llt will be observed that this partially formed spoke, which will bedesignated by the reference character A, is formed in effect in a doubleor twin section, substantially symmetrical about a longitudinal centerline, the two halves of this double but one-piece section beingseparated by a longitudinal groove or depression 11 extending from thehub end up to but not through the felloe end shown at the left hand endof the partially formed spoke. 'lhat is to say, this longitudinaldepression extends substantially but not quite the full length of thepartially formed spoke. 1n this operation the felloe end designated 12is roughly formed, the body portion designated 13, formed in two halveson opposite sides of the depression are shaped up, the spoke is flaredoutwardly as shown at 1d, joining the body portions 13 and the enlargedtapered or wedgeshaped portions 15. Likewise in this operation there areformed on the faces 16 which subsequently become the opposite relativelytapered faces of the wedgeshaped hub portion, an interlocking depression17 and an interlocking projection 18. Adjoining thedepression andprojection 17 and 18 are formed ,depressions 19 substantiallysemi-circular in form, which depressions are utilized to accommodate thehub bolts as already explained. 0n opposite sides mesma of thedepression 17 and depression 19 of one enlarged portion 15, and onopposite sides of ,so that they may be formed into the seam.

ln lthe second spoke forming operation the partially formed spokedesignated B in Figs. 6 and 7 is formed. lln Figs. 6 and 7 ll haveillustrated simply the ends of the partially formed spoke B, since theplan and side elevation thereof are substantially like the plan and sideelevation of the partially formed spoke A produced by the first spokeforming operation and illustrated in Figs. 2 and 3. lln producing thepartially formed spoke A in the first spoke forming operation, due tothe drawing of the metal, the edges or inarginal portions 21 and 22 areof irregular shape, and there is usually a surplus of metal. lin thesecond spoke forming operation the surplus metal is cut off and theedges are trimmed and also given the shape illustrated in Figs. 6 and 7wherein one edge designated 23 is extended upwardly, and the otherdesignated 24 is extended downwardly to adapt these edges for the beadforming operation. Likewise, in this second spoke forniing operation thecorners at the hub portion are formed sharp, all depressions andprojections lat the hub portion, thoroughly formed. Likewise in thisoperation the partially formed spoke is given a smooth finish and allwrinkles are pressed out. Suitably shaped dies are utilized to performthese several functions and to accomplish the results as stated.

ln the third spokeforming operation the partially formed spoke B isconverted to the partially formed spoke C designated in Figs. 8 to 11.llt will be observed that in this operation the two halves of the doublesection are nearly closed, and that in this operation the devicesubstantially assumes the form of the finished spoke, that is to say,though the edges or marginal portions 23 and 24 lare brought up close toeach other, as most clearly shown in Figs. 10 and 11, they are stillseparated by a slot extending the full length of the partially formedspoke C, but the felloe end, here designated 25 is brought intosubstantially circular shape, the body portion here designated 26 ismade into nearly the finished tapered tubular shape. and lthewedge-shaped hub portion here designated 27 isbrOught to substantiallyits form, However, the sides of the lill@ of the center line,

I 'forming operation wherein the partially completed spoke designated Din Figs. 16 to 20 is formed.v As this operation 1s extremely importantto the e'ectiveness j of the spoke, in the way of stren h and durabilityas well *asl desi' an appearance, the steps or ortions o this operatlonhave been fully i ustrated in the diagrammatic views of Figs 12 to 15.In this operation special dies are utilized, and while these diesconstitute the subject matter of a companion application, I have shown aportion thereof so that the closing and bead forming operation will bebetter understood.

` In this o eration a mandrel is utilized having a ong the top alongitudinally extending slot 30a in which the seam is formed. Thepartiell closed, partiall formed spoke C is slippe onto this man relwhich lies between av pair of jaws 31, shaped to correspond to theoutline of the finished spoke. These jaws which in the preferredconstrueu tion of the dies are pivoted at one end, are swung inward bycams 32 carried by the upper die, so that as the upper die descends, thefirst operation is to close the tubular spoke, bringing the edges 23andl 24- together, or in contact with each other, as shown in Fig. 12.YAs the upper die continues to descend, one of` two relatively slidablepunches which operate in sequence is operated. The punch which is firstoperated, is designated 33, this punch engagingl with a portion of theedge 2A ofthe metal which projects beyond the edge 23, bending itdownward as'illustrated in Fig. 13. Then the second punch which isdesignated 34, descends in the manner illustrated in Fig.

\ 14, and presses the edges or marginal portions 23 and 24: into theslot 30a of the mandrel, and on the completion of the stroke forms thefinished seam which is designated 35 in Fig. 15. This seam extends thefull length of the spoke and forms a double lock which holds the metalagainst spread-.

ing or pulling apart and immensely strengthens the spoke, as will' bereadily understood.

0n the retraction of the upper die, the jaws spread apart and thepartially formed spoke D is stripped from the mandrel. This partiallyformed spoke D is substantially the completed spoke, and it di'ers fromthe completed spoke only in the respect that at the extreme hub end, i.e. beyond the hub bolt depressions 19 it is curved about thelongitudinal axis of the spoke as indicated at 36, this curvaturebein ontwo opposite sides of the hub end o the spoke, j

while the other two sides at the hub end are ,flat and parallel, asclearly indicated -in' FiA 20. The purpose of forming the hub en of thespoke with the two opposite curved sides 36 is to permitA the artiallyformed spoke D to be stripped fli'om the mandrel 30. The large endof themanfdrel corresponds to the shape of the artially formed spoke D at fits hub en as illustrated'in 'F1g. 20,'so that the Partially formedspoke D can be slipped rom the mandrel, following the fourth spokeforming operation illustrated in Figs. 12 to 15.

In the fifth spoke formingoperation the hub end of the spoke iscompressed in a special sizing die, thesole function of which is toHatten out the curvatures 36 shown in Figs. 16 and 20, so as to convertthem to fiat faces tapered in conformity with the taper of these facesbeyond the hub bolt depres sions. As already stated, these tapered faceson opposite sides of the hubv portions of the spoke are designed toengage the corresponding tapered faces of the adjacent spokes, andtherefore the angle of these tapered faces of each spoke will dependupon the number of spokes in the whee In this operation there is,therefore produced the finishedspoke Ewhich I'have i1- lustrated inFigs. 19, 20 and 21. Although the details of this spoke are claimed inmy application Serial No. 487,292, filed July 25, 1921, it might bestated. in conclusion that this finished spoke is .provided with areduced felloe end, which is adapted to engage the felloe and may besecured thereto in any suitable way: also the slightlyltapered tubularbody d beyond which is the outwardly flared part d2 adjoining thewedge-shaped hub portion d3 which hub portion has two opposite fiatfaces which are adapted tobe clamped against the inner faces of theflanges of the hub; and two tapered faces which are tapered from the endof the outwardly flared portion (Z2 to the extreme hub end of the spoke.In these tapered faces there are the semi-circular hub bolt depressionsd* which when the spokes are assembled, form cylindrical openings forthe hub bolts, and likewise there are formed in one of these taperedlfaces a. depression indicated at d5, and on the other tapered face aprojection indicated at d". It is understood that the de-V pressions d5and the projections d of the several spokes interlock lwhen the spokesare assembled, locking the spokes against relative movement, and alsoaligning them to the n.25

-bolt depression al4 While the remainder of thetapered faces are flat oruninterrupted. llt may be desirable to provide the interlockingdepression and extension also on those portions of the tapered faceslocated toward the hub end from the hub bolt depressions d in order toprovide an additional interlock. ln other words, the depression d5 andthe projection al would then extend for the full length of the taperedfaces, except for the hub bolt depressions d4. 'lhis modifiedconstruction l have illustrated in lFigs.-22 and 23, wherein l haveshown simply the hub end of the spoke which l have designated by thereference character D. l

While l have shown the preferred method of forming the spoke, whereinafter the blank is punched from the strip of sheet metal the spoke isformed by live spoke forming operations wherein deformations are madeand various other operations are performed, and while as ll now believe,the spoke can best be formed by these operations, in each of which adistinct step toward the completion of the spoke is accomplished,nevertheless, ll do not desire to be confined to the precise number ofoperations, or to the precise details or features of the operationsdescribed, but aim in my claims to cover all modifications which do notinvolve a departure from the spirit and scope of the invention assetforth in the appended claims.

Having described my inventioinll claim:

1. The method of forming a tubular sheet v metal spoke which comprisesdeforming a suitably shaped blank so as to produce a partially formedspoke in a double or twin section, the halves of which are substantiallysymmetrical abo`ut a longitudinal center line land divided bya'longitudinally extending groove or depression, and subsequentlyclosing together the two halves and securing their edges together.

A2. The method of forming a tubular onepiece sheetv metal spoke with an'enlarged tapered hub portion, which comprises pressing and drawing ablank so as to produce an f open twin or double one-piece section, eachhalf thereof adapted to form substantially one-half of the completedspoke, and subsequently closing the two halves together and lockingtheir edges in the form of a seam extending lengthwise of the spoke.

The method of forming a tubular sheet spoke. with an enlargedwedge-shaped hub portion, which comprises deforming a properly shapedblank so as to produce a double or twin one-piece section, each halfthereof corresponding substantially to the shape of one-half of thespoke, the section thus formed being substantially symmetrical about thelongitudinal center line-thereof,

and subsequently closing the two halves and uniting their edges in theform of a seam extending longitudinally of the spoke.

4c. The method of forming a tubular sheet linearer metal one-piece spokewith an enlarged wedge-shaped hub portion, lwhich comprises deforming asuitab y shaped blank so asJto produce a double or twin one-piecesection, each half thereof corresponding in shape to substantiallyone-half the spoke, closing the two halves together and unitingtheir'edges on an inner mandrel, withdrawing the partially formed spokefrom the mandrel and subsequently forming the hub end into the inalwedge-shaped form. v

5. rllhe method of forming a tubular sheet metal one-piece spoke with anenlarged wedge-shaped hub portion, which comprises deforming a suitablyshaped blank into a double or twin one-piece section substantiallysymmetrical about a longitudinal center line thereof, trimming andshaping the edges thereof so that they may be interlocked, bringing thetwo halves together, and locking their edges in the form of a seamextending the length of the spokea 6. 'lhe method of forming a tubularsheet metal one-piece spoke with an enlarged wedge-shaped hub portion,which comprises deforming a suitably shaped blank into a double or twinone-piece section substantially symmetrical about a longitudinal centerline thereof, trimming and shaping the edges thereof so that they may beinterlocked, bringing 'the two halves together, locking their edges inthe form of a seam extending the length' of the spoke, withdrawing thepartially formed spoke from the mandrel, and subsequently reducing andshaping the hub end of the spoke.

7. 'lhe method of forming a tubular sheet metal one-piece spoke for avehicle wheel, which comprises deforming a properly shaped blank so asto form a double or twin one-piece section substantially symmetricalabout the longitudinal center line, each half correspondingsubstantially to one-half thel completed spoke, and including a taperedbody portion and an enlarged hub portion, and closing the two halvestogether and uniting their edges.

8. The method of forming a tubular sheet metal one-piece spoke forvehicle wheels, which comprises deforming a .suitably shaped blank so asto provide a double or twin one-piece section substantially symmetrical.about the longitudinal center line, each corresponding in shapesubstantially to one-half the shape of the spoke to be formed, and eachbeing provided with a body forming portion and with an enlarged hubforming portion, the hub forming portions of the two halves havingsimilar transverse depressions, and subsequently bringing the two halvestogether and uniting their edges.

9. The method of forming a tubular sheet metal one-piece spoke forvehicle wheels, which comprises deforming a suitably shaped blank s0 asto provide a double or twin one-piece section substantiaiiy ysym:metrieai about the longitudinal center line, erich corresponding inshape to substantiaiiy one haii the spoke to be formed, and

' eaeh being provided with a body forming portion and with en enlargedhub forming portion, the hub forming portions ,of the two halves havingsimilar transverse depressions, subsequentiy bringing 4the two halvestogether and uniting 1their edges in the form of a locked seam, the'seam'being orme in a. mandrel, and suuently withdrawing the partiallyformed spoke from the mandrl, and reucing and 1re-*shaping thek hub en yIntestimony whereof, l hereunto e my signature.

@HQE/MS N, AKEN

